The Project Files

The Build

We begin this project by making our piece of plywood flexible, so we can simulate some waviness into the flag.

The are many clever patterns that can cut into rigid materials to make them more flexible. For this project we chose a pattern from koFAKTORlab. You can find a link to their site at the end of this article.

Cut pattern used to add flexibility to our plywood.

This pattern is very intricate and took quite a while to cut. It was worth the wait.

Watch the cutting process.

Cutting process completed.

Our solid plywood is transformed into a flexible material.

Although the plywood is now very flexible, it is still somewhat delicate. Be careful when handling as it will only bend up to a limit before it breaks. Here’s how I know this!

Whoops!

I was recommended a technique to help prepare the wood surface for painting. Methylated spirits is rubbed over the bare wood. This is absorbed into the wood fibres and causes them to swell. Once evaporated, the fine fibres can removed with a light sanding. This leaves a perfect surface for painting.